Replaceable battery pack for intra-oral larynx

ABSTRACT

An intra-oral artificial larynx is provided including a signal generator and a speaker mounted on a prosthesis for mounting the larynx within the intra-oral cavity. A horn is provided having an input opening coupled to the speaker for acoustically amplifying the output of the speaker, the horn also having an output opening. A saliva barrier is removably mounted to the output opening of the horn for precluding penetration of saliva into the horn, the barrier having a first end which is telescopically received within the output opening of the horn and the second end having a mouth formed on a bias to the longitudinal axis of the mounting and a microporous membrane sealing the mouth. The mouth of the mounting has an elliptical shape which has been found tends to increase speaker volume. Moreover, the telescopic mating of the mounting and the horn provides a saliva barrier which is easily replaceable by the user.

RELATED APPLICATIONS

The present application is related to Ser. No. 438,376, filed Nov. 1, 1982, which is a continuation-in-part of Ser. No. 249,140 filed Mar. 30, 1981 and is further related to Ser. No. 428,848 filed Sept. 30, 1982 which is a continuation of Ser. No. 249,140 filed Mar. 30, 1981, all of which are incorporated herein by reference as if fully set forth in full.

BACKGROUND OF THE INVENTION

The present invention relates, in general, to the field of sound producing prosthetic devices for use by laryngectomized patients, and in particular, relates to a self-contained intra-oral artificial larynx and an improved battery pack therefor.

Many devices have been suggested for providing speech capability to laryngectomized patients. The most successful and important of these devices known to the present applicants is the artificial larynx described in detail in copending application Ser. No. 438,376, filed Nov. 1, 1982 by Henry S. Brenman, Philip Katz, Louis D. Lowry and Harold Schwartz which is mentioned above. In that application, various prior art techniques of artificially producing speech by a laryngectomized patient are discussed. Unlike the prior art devices which had relied upon extra-oral components, the device disclosed and claimed by Brenman et al is one which resides entirely within the mouth of the patient and which is incapable of visual detection.

The device disclosed and claimed by Brenman et al includes, inter alia, a power source, a signal generator, a speaker and tongue activated switches, all of which are mounted to a dental prosthesis and situated within the wearer's mouth. All of the aforementioned components, as well as others, are formed in the body of a dental prosthesis which is formed of conventional dental prosthetic materials, such as an acrylic polymer, which is shaped to fit comfortably against the roof of the wearer's mouth.

Because all of the components of the Brenman et al device are situated on an intra-oral dental appliance, a maximum size constraint greatly affects the power source which may be employed. The power source must be extremely thin because the dental appliance fits against the roof of the mouth. If the appliance is unduly thick it provides an obstacle to swallowing. Because the power supply is subjected to a severe maximum size constraint, Brenman et al employ a unique combination of tongue controls for permitting convenient intermittent use, novel power saving circuitry and tuned acoustic amplification to permit the artificial larynx to be used for longer periods before the power source is exhausted. In the preferred embodiment of the device disclosed and claimed by Brenman et al, the batteries are entirely sealed within the dental prosthesis such that the use of replacement of the batteries is impossible. Brenman et al suggest that alternate embodiments may exist wherein batteries may be replaced.

In copending application Ser. No. 547,777 filed Nov. 1, 1983 which is a continuation-in-part of Ser. No. 438,376 filed Nov. 1, 1982 mentioned above, Brenman et al further disclose and claim one such alternate embodiment. In that alternate embodiment, batteries are placed in a carrier which is slideably received in a compartment formed in the dental appliance. The present application claims features which are an improvement to the slideably and removably mounted power source disclosed and claimed in Ser. No. 547,777 filed Nov. 1, 1983 by Brenman et al.

The provision of an intra-oral artificial larynx having replaceable batteries is not without difficulty. In order to provide a larynx having replaceable batteries, it is necessary to provide a dental appliance having an opening therein to a battery compartment. Such an opening to the battery compartment creates certain problems. First, the opening provides a route for the invasion of saliva into the battery or power source compartment of the artificial larynx. Saliva, however, is conductive, and may cause the batteries to short circuit which, in turn, causes the artificial larynx to be rendered inoperative. Secondly, the saliva, being conductive, may cause corrosion between the anode and cathode of the batteries. The corrosion may be harmful to, not only the artificial larynx itself, but to the patient as well. Thirdly, if the battery compartment is not adequately sealed, the batteries may become dislodged and swallowed which may be harmful to the patient.

Another difficulty encountered in providing replaceable batteries for an intra-oral artificial larynx resides in the fact that the batteries are, and of necessity must be, relatively small thus causing them to be difficult to manipulate with the fingers. This is especially true for older and perhaps handicapped patients. It may be difficult for such patients to manipulate the small batteries required for the intra-oral artificial larynx. It may also be particularly difficult to ensure that the batteries when inserted are properly inserted with the correct polarity.

It would be desirable to provide an intra-oral artificial larynx which does not suffer from the aforementioned disadvantages. It would be further desirable to provide an intra-oral artificial larynx having a removable battery pack.

It is still further desirable to provide an intra-oral artificial larynx with a removable battery pack which, when in place, is completely sealed from saliva found in the intra-oral cavity.

It would still be further desirable to provide such an artificial intra-oral larynx having a battery pack which is easily inserted and removed.

It would be still further desirable to provide such a battery pack in a form such that the insertion of batteries having incorrect polarity is minimized or avoided.

SUMMARY OF THE INVENTION

These and other objectives of the present invention are achieved by the provision of an intra-oral larynx having a prosthetic means for mounting the larynx within the intra-oral cavity. The larynx includes a signal generator and a speaker mounted on the prosthetic means and a tongue activatable switch for enabling the signal generator and speaker. A compartment is provided for slideably receiving a power source, the compartment having a lip around the opening thereof. A power source is mounted on a carrier, the carrier being slideably and removably mounted in the compartment. In accordance with an important aspect of the present invention, the carrier includes an integral sealing portion which mates with the lip of the compartment for isolating the interior of the compartment and the power source from saliva and the intra-oral cavity.

In accordance with an important aspect of the present invention, the integral sealing portion comprises a beveled edge which frictionally engages and mates with the lip.

In accordance with still another important aspect of the present invention, the carrier for the aforementioned power source is provided with a means for ensuring that the power source is mounted in the compartment with the correct polarity alignment. Specifically, both the carrier and compartment are formed to have an asymmetric shape such that the carrier may only be completely engaged within the compartment when the carrier has the correct orientation.

In accordance with still another important aspect of the present invention, the carrier includes a handle portion which projects from the prosthesis and which operates in conjunction with a gripping means for removing the carrier and the batteries from the prosthesis at the time of battery replacement.

In accordance with still another important aspect of the present invention, a method of forming an ultra-thin artificial larynx having a removable battery pack is disclosed. This method comprises the placing of the aforementioned signal generator, speaker and tongue activatable switches in a mold. The method further includes the step of placing of a power source compartment cover in the mold and the locating of a power source compartment blank within the cover in the mold. After the signal generator, speaker and tongue activatable switches are encapsulated, the aforementioned blank is removed, thereby forming a power source compartment.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be more fully understood by reference to the accompanying drawings in which:

FIG. 1 is a diagrammatic plan view of the bottom surface of a preferred embodiment of an artificial larynx, illustrating the speaker, acoustic horn, tongue contacts, circuitry and power source within an otherwise conventional dental prosthesis;

FIG. 2 is a cross-sectional view of the larynx of FIG. 1 taken along section lines 2--2 illustrating the acoustic horn and an improved saliva barrier;

FIG. 3 is a block diagram illustrating the operative electrical components of the preferred embodiment of the artificial larynx of the present invention;

FIG. 4 is a cross-sectional view of the artificial larynx of FIG. 1 taken along section lines 4--4; and

FIG. 5 is a top view of a power source carrier for the power source of the larynx of FIG. 1, the carrier being slideably engageable with the prosthesis shown in that figure;

FIG. 6 is a cross-sectional view of the carrier of FIG. 4 taken along section lines 6--6; and

FIG. 7 is a diagrammatic perspective view showing the removal of the carrier of FIG. 5 from the prosthesis of FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to FIG. 1, the intra-oral artificial larynx of the present invention will be seen generally at 10. As shown in FIG. 1, the larynx 10 is shown in position against the roof of the intra-oral cavity of the patient. The larynx of FIG. 1 comprises a prosthetic means, designated generally at 12, which comprises a conventional, palatal denture or dental prosthesis. Such a prosthesis usually comprises a means for anchoring the prosthesis in the mouth cavity; such means in FIG. 1 being dental wires 14 and 16. The body 18 of the dental prosthesis 12 is formed from conventional dental prosthetic materials, such as an acrylic polymer, which is shaped to fit against the roof of the mouth. The body 18 of the prosthesis is preferably formed to encapsulate all of the electrical components of the preferred embodiment of the larynx. Specifically, the body 18 encapsulates a signal generating circuit 20 for generating a preselected electrical signal. It also encapsulates a speaker 22 for converting the signal into acoustic energy. The body 18 of the molded prosthesis 12 also encapsulates an acoustic horn 24 which is the preferred acoustic amplification means for amplifying acoustic energy generated by the speaker 22. As shown in FIG. 1, the preferred acoustic horn 24 is conical, having its minimum diameter at its juncture with the speaker 22 and its maximum diameter at its terminus 26 at the rear of the prosthesis 12.

The larynx 10 of the present invention is controlled by switches 28 and 30 pressed with the tongue. As is described more fully hereinafter, the touching of either of these switches act to complete a ground path in the larynx.

The efficiency of the sound circuitry of the present invention makes it possible to use a low voltage, low current power source. The power source is situated in a power source compartment 32 which is formed in the body 18 of the prosthesis by a method to be described below. For the embodiment of FIG. 1, the power source may comprise lithium, silver oxide or nickel cadmium or other rechargeable type batteries recharged by any means. In accordance with the most important aspect of the present invention, the power source located in the power source compartment 32 of FIG. 1 is removable and replaceable with ease. This feature of the present invention will be described in detail in connection with FIGS. 4 through 7 below.

Special precautions are taken to prevent the speaker 22 from becoming fouled with water or saliva. In addition to increasing the amplitude of the sound generated by the speaker 22, the acoustic horn 24 aids in protecting the speaker 22 from liquids contained within the mouth. This protection results from the location of the speaker at the extreme proximate end of the horn. Additional protection against flooding of the speaker 22 may be attained by covering the mouth 26 of the horn 24 with a thin sheet of material which will prevent liquids from entering the horn but which will permit water vapor and air to pass therethrough. Hydrophobic, microporous material such as polytetrafluoroethylene sheets (half mil) sold under the tradename "Teflon FEP fluorocarbon film" by American Durafilm Company, Inc. of Newton, Lower Falls, Mass., are suitable for this purpose.

The microporous saliva barrier must be replaced periodically by the patient. In accordance with one aspect of an invention disclosed in copending application Ser. No. 547,740 filed Nov. 1, 1983 and copending application Ser. No. 547,772 filed Nov. 1, 1983, the saliva barrier is fixed to a removable saliva barrier cartridge which, in turn, is removably attached to the mouth 26 of the horn 24. In this manner, the saliva barrier cartridge may be pre-packaged and is disposable such that replacement of the microporous saliva barrier membrane may be accomplished readily, even by handicapped patients.

Referring now to FIG. 2, the saliva barrier cartridge, as well as the details of its attachment to the mouth 26 of the horn 24 will be described. As shown in FIG. 2, the microporous saliva barrier 40 is part of an overall saliva barrier cartridge shown generally at 42. The cartridge 42 includes a mounting 44 which is preferably a truncated conical structure, having a central opening 46 therein. The saliva barrier membrane 40 is affixed to the mounting 44 by means of an O-ring 48, which tightly engages the outer surface of the mounting and compresses the membrane 40 against it. The entire saliva barrier cartridge 42 is removably attached to the mouth 26 of the horn 24. The external end of the horn 24 includes a region 50 of reduced diameter which mates with the central opening 46 of the mounting 44. The region 50 of reduced diameter includes a pair of peripheral grooves in which O-rings 52 and 54 are provided to maintain the cartridge 42 in frictional engagement with the horn 24 and further to preclude penetration of saliva to the interior of the horn 24.

From FIG. 2, it will be seen that the external opening of the mounting 44 is formed on a bias to the longitudinal axis thereof, such that the central opening 46 of the mounting is elliptical in cross-section when viewed from a direction normal to the saliva barrier surface as shown at arrow 56. It has been found that the provision of an elliptical opening to the horn 24 increases speaker volume. It has further been found that the rotational orientation of that elliptical opening further effects speaker volume. Since the mounting 44 is rotatable about its longitudinal axis even when engaged with the horn 24, the user of the larynx 10 may vary the angular orientation of the saliva barrier 40 so as to maximize speaker volume.

FIG. 3 provides further information concerning the operation of the preferred embodiment larynx 10 of the present invention. As shown in FIG. 3, the signal generation circuitry of the present invention is seen to comprise a signal generator 200 and differentiator 202. In the preferred embodiment, a square wave signal generator is utilized, the resultant signal of which is differentiated to produce an output signal comprising a plurality of spikes which are separated by long, near-zero voltage time periods. In the preferred embodiment, the square wave signal generator comprises an astable multivibrator which generates a signal having a frequency between zero and 20 kHz, preferably 60-120 Hz. By differentiating the signal generator output, the frequency and maximum amplitudes of the positive and negatives spikes produced thereby will, of course, correspond to the frequency and amplitude of the square wave signal. The periods of return to near-zero voltage between spikes of the differentiated signal are too short to be audibly resolved, and thus, "audio flicker" is created when the output signal is fed to audio amplifier 212 to produce the output tone of the larynx. Thus, the amplitude and frequency of the apparent sound produced by the larynx has not been changed, while the duty cycle, and thus the power drain of the output signal has been substantially reduced. A duty cycle control means is thus provided which is utilized to reduce the duty cycle of the output of the signal generation means by profitably utilizing the audio flicker effect. In the preferred embodiment, the duty cycle of the signal generation means is at least less than 10 percent, generally less than 5 percent, and most preferably less than about 1 percent. In fact, good results have been obtained using a duty cycle of about 0.85 percent.

The preferred embodiment artificial larynx further comprises a tongue activatable intra-oral switching device. This switching device comprises an ON-OFF circuit for activating or deactivating the device. This selective enabling and disabling function is accomplished by providing at timing means for timing the closure of the switch, which, in the preferred embodiment, is accomplished by completion of a ground path through switches 28 or 30. The desired grounding may be accomplished by bridging between adjacent contacts with the tongue or by using the body as the system's ground whereby touching a single contact will accomplish a grounding of the system. In this embodiment, counter 204 counts in response to the output of the signal generation means when the ON-OFF switch 28 is grounded, but is inhibited from counting when the ON-OFF contacts are not grounded. In order to turn on the artificial larynx 10, the tongue is held against "ON-OFF" switch 28 until counter 204 has been permitted to count for a preselected period of time, after which an output pulse is provided to differentiator and inverter 206. The output pulse of counter 204 is thus differentiated and inverted in 206 in order to provide a distinct output to bistable multivibrator (flip-flop) device 208, which is caused to assume its "ON" position. When in this position, flip-flop 208 provides a high level signal to "AND" gate 210, then the differentiated output of the signal generator 200 will be permitted to pass to high gain amplifier 212 and thereafter to speaker 22. When the user hears the signal from speaker 22, the tongue may be removed from ON-OFF switch 28, and the flip-flop 208 will remain in its "ON" position.

Referring now to FIGS. 4 through 7, an improved battery pack for powering the circuit of FIG. 3 will be described in detail. The battery pack to be described is removably and slideably mounted in the power source compartment 32. The power source compartment 32 comprises a cavity formed in the body 18 of the prosthesis 12. Entry to the battery compartment 32 is by way of an opening 60 having a slight depression or lip 67 around the periphery thereof. The battery compartment 32 is formed in part by means of a battery compartment cover 64 which is embedded within the encapsulation material forming the body 18 of the prosthesis 12. The compartment cover 64 forms the walls and top of the battery compartment 32. The floor 66 of the compartment, however, is formed directly of the encapsulation material of the body 18 of the prosthesis. Fixedly attached to the undersurface of the compartment cover 44 are anode contacts 68 and 70. Situated on the floor 66 of the compartment 32 are cathode contacts 72 and 74. When the batteries powering the larynx are in place, the anodes of the batteries are in ohmic contact with anode contacts 68 and 70 while the cathodes are in ohmic contact with the cathode contacts 72 and 74, respectively. The contacts 68, 70, 72 and 74 are, of course, electrically connected to the circuitry described above.

In accordance with the preferred embodiment of the present invention, the batteries are inserted within the battery compartment 32, while affixed to a carrier shown in FIGS. 5 and 6. The carrier 76 is slideably and removably received within the compartment 32. The carrier 76 is formed in the shape of a relatively flat panel having apertures 78 and 80 formed therein. Situated within each of the apertures 78 and 80 are two batteries in side-by-side relationship. As mentioned above, such batteries are of the lithium, silver oxide or nickel cadmium type. The carrier 76 is formed of an electrically insulating material so as to electrically isolate each battery from the other. Preferably, the carrier 76 is formed of a molded silicone. When in place, the anodes and cathodes of the batteries project slightly above the planar surfaces of the carrier 76 so as to contact the anode contacts 68 and 70 and the cathode contacts 72 and 74 mentioned above.

In accordance with an important aspect of the present invention, the carrier 76 includes an integral sealing portion 80 which mates with the lip 62 around the opening 60 to the battery compartment 32 so as to isolate the interior of the compartment from saliva in the intra-oral cavity. In the particularly preferred embodiment, the sealing portion 80 comprises a beveled edge which frictionally engages and mates with the lip to form an extremely watertight seal between the interior of the battery compartment and the exterior thereof. In accordance with still another important aspect of the present invention, the carrier 76 includes a means for ensuring that the batteries, when mounted in the compartment 32, are oriented such that they have the correct polarity alignment. This is accomplished by the provision of the rounded portion 84 at the leading edge of the carrier 76. As may be seen from FIG. 1, the battery compartment 32 has a corresponding curved edge 86 as shown. For this reason, both the carrier 76 and the compartment 32 are asymmetric. In this manner, complete engagement between the carrier 76 and the compartment 32 is only achievable in one and only one orientation. This feature ensures that power sources mounted in the battery compartment 32 always have the correct polarity alignment.

In accordance with still another important aspect of the present invention, a means is provided for easy insertion and removal of the battery pack of the present invention. This means preferably comprises a reinforced handle portion 88 which projects from the opening 60 of the battery compartment 32 when the carrier 76 is in place. The handle portion 88 further includes a transverse bore 90. The bore or hole 90 mates with a gripping means which assists in the insertion or removal of the carrier 76 from the compartment 32.

As may best be seen in FIG. 7, this gripping means 92 may include a loop portion 94 for finger engagement and a hook portion for engagement with the bore or opening 90 of the carrier 76. As shown in FIG. 7, the gripping means 92 may be used both to insert and to extract the power source and carrier 76 from the battery compartment 32.

While a particular embodiment of the present invention has been shown and described, it will be appreciated that other embodiments will occur to persons skilled in the art, and accordingly, all such embodiments are within the spirit and scope of the appended claims. 

We claim:
 1. An intra-oral artificial larynx comprising:prosthetic means for mounting said larynx within the intra-oral cavity; signal generation means mounted on said prosthetic means for generating a preselected electrical signal; speaker means mounted on said prosthetic means for converting said signal into acoustic energy; a tongue activatable switch for enabling said signal generation means and said speaker means; a compartment for slideably receiving a power source, said compartment having a lip around the opening thereto; and a power source mounted on a carrier, said carrier being slideably and removably mounted in said compartment, said carrier including an integral sealing portion mating with said lip for isolating the interior of said compartment and said power source from saliva in the intra-oral cavity.
 2. The carrier of claim 1 wherein said sealing portion of said carrier comprises:a beveled edge which frictionally engages and mates with said lip to isolate the interior of said compartment from saliva in said intra-oral cavity.
 3. The intra-oral artificial larynx of claim 1 wherein:said carrier includes a means for ensuring that said power source is mounted in said compartment with said power source having the correct polarity alignment.
 4. The intra-oral artificial larynx of claim 1 wherein:said carrier and said compartment are both being asymmetric whereby complete engagement between said carrier and said compartment ensures that said power source is mounted in said prosthetic means with the power source having the correct polarity alignment.
 5. The intra-oral artificial larynx of claim 1 wherein:said carrier includes a handle portion projecting from said compartment for aiding in insertion and removal thereof.
 6. The intra-oral artificial larynx of claim 5 further comprising:a gripping means engageable with said handle portion for assisting in the insertion and removal of said carrier from said compartment.
 7. An intra-oral artificial larynx, comprising:custom molded prosthetic means for mounting said larynx within the intra-oral cavity; signal generation means encapsulated within said custom-molded prosthetic means for generating a preselected electrical signal; speaker means at least partially encapsulated within said custom-molded prosthetic means for converting said signal into acoustic energy; a tongue activatable switch for enabling said signal generation means and said speaker means; a compartment molded in said custom-molded prosthetic means for receiving a power source for said signal generation means; and a plurality of power sources mounted on a carrier, said carrier being removably mounted in said compartment, said carrier comprising a panel having apertures therein, each for receiving a separate power source, electrical contact to each such source being made on opposite surfaces of said panel.
 8. The intra-oral artificial larynx of claim 7 wherein:said panel is formed of an electrically insulating material for electrically isolating each power source from another.
 9. The intra-oral artificial larynx of claim 8 wherein:said electrically insulating material is molded silicone.
 10. The intra-oral artificial larynx of claim 8 wherein:said carrier further includes a sealing portion mating with said prosthetic means for isolating the interior of said compartment and said power source from saliva in the intra-oral cavity.
 11. The carrier of claim 10 wherein said sealing portion mates with a lip around the opening of said compartment.
 12. The carrier of claim 11 wherein said sealing portion of said carrier comprises:a beveled edge which frictionally engages and mates with said lip to isolate the interior of said compartment from saliva in said intra-oral cavity.
 13. The intra-oral artificial larynx of claim 7 wherein:said compartment and said carrier are both asymmetric whereby full engagement between said carrier and said compartment ensures that said power source is mounted in said compartment with the power source having the correct polarity alignment.
 14. The intra-oral artificial larynx of claim 13 wherein:said carrier includes a handle portion projecting from said compartment for aiding in the insertion and removal thereof.
 15. The intra-oral artificial larynx of claim 14 further comprising:a gripping means engageable with said handle portion for assisting in the insertion and removal of said carrier from said compartment.
 16. A method of fabricating an intra-oral artificial larynx comprising:placing a signal generation means, a speaker means and a tongue activatable switch in a mold; placing a power source compartment cover in said mold; locating a power source compartment blank within said cover in said mold; encapsulating said signal generation means, said speaker means, said tongue activatable switch, said compartment cover and said blank with molding material; curing said molding material to form a custom-molded prosthetic means; and thereafter removing said blank from said compartment cover to form a power source compartment.
 17. A removable power source for an intra-oral artificial larynx of the type having:a prosthetic means for mounting said larynx within the intra-oral cavity; a signal generation means mounted on said prosthetic means for generating a preselected electrical signal; speaker means mounted on said prosthetic means for converting said signal into acoustic energy; a tongue activatable switch for enabling said signal generation means and said speaker means; and a compartment for slideably receiving the power source, said compartment having a lip around the opening thereto; said power source comprising: batteries mounted on a carrier, said carrier being slideably and removably mounted in said compartment, said carrier including an integral sealing portion mating with said lip for isolating the interior of said compartment from saliva in the intra-oral cavity.
 18. The power source of claim 17 wherein said sealing portion of said carrier comprises:a beveled edge which frictionally engages and mates with said lip to isolate the interior of said compartment from saliva in said intra-oral cavity.
 19. The power source of claim 17 wherein:said carrier includes a means for ensuring that said batteries are mounted in said compartment with the correct polarity alignment.
 20. The power source of claim 17 wherein:said carrier includes a handle portion projecting from said compartment for aiding in insertion and removal thereof. 